I finally found the time to complete my 60AH LiFePO4 battery by building it into a box this weekend between sporting events for my daughter.
I had checked the size of the four battery cells prior to ordering them and they seemed to fit into a Plano 1612 Deep Water Resistant Field Box. I toyed with the idea of putting the Power Pole connector into the compartment on the top cover, but it seemed to put too much stress on the 10 AWG wiring when the cover was open, so I cut a small rectangular opening in one end of the box and used a pair of Mounting Clamps to mount the Power Pole connector. The clamps were affixed with 3mm diameter, 6mm long self-tapping screws for plastic from screwerk.com. Due to the metric size, they required a #44 drill bit.
The battery was form fitted to the box using some closed-cell high density foam pads cut to size. Finally the Power Control Module was isolated from the battery and the plastic box (it gets warm during charging) with a couple of pieces of 6×6 inch vulcanized fiber board (this is a UL rated high-temp insulating material). This sort of material is commonly used in the fabrication of electric guitar pickups so it can be found cheaply on Ebay.
The small compartment on the lid holds a watt-hour meter and Power Pole six outlet power tap and spare fuses.
60AH Battery Pack in a box
